5 november 2008 evoluon - eindhoven omro n lcia bram kale european engineering manager. omron omron...
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5 november 2008
Evoluon - Eindhoven OMRON
LCIABram KaleEuropean Engineering manager
.OMRON
Omron Europe B.V
5 november 2008
Evoluon - Eindhoven OMRON
OMRON Industrial automation
• Japanese multinational• 35.000 employees• 5.8 Billion in Euro• Industrial automation products
PLC’sPLC’s
Card-ReadersCard-Readers
Human Machine Human Machine InterfaceInterface
Motion Control (OYMC)Motion Control (OYMC)
Vision & ID systemsVision & ID systems
Timers & CountersTimers & Counters SensorsSensors
5 november 2008
Evoluon - Eindhoven OMRON
Engineering
SMT automated production
AssemblyManual productionLCIA assembly
5 november 2008
Evoluon - Eindhoven OMRON
LCIA Assembly
• DescriptionLCIA – Low Cost
Intelligent Automation is a system for effective manual production, where manual stages, simple control systems and clever tools are integrated to a flexible, productive and high quality method of assembly.
5 november 2008
Evoluon - Eindhoven OMRON
5 november 2008
Evoluon - Eindhoven OMRON
LCIA assembly
• Productivity improvement
• Reduction of Quality problems
• Increase production Flexibility
Focus points:
5 november 2008
Evoluon - Eindhoven OMRON
2. Synchronization of Chain of Processes
1. Consequent Elimination of Waste[Muda]
Anchor in theline set up
Drivers of the system
LCIA assembly
-Overproduction-Waiting time-Transportation-Processing-Inventory-Motion-Product defect
5 november 2008
Evoluon - Eindhoven OMRON
LCIA assembly
Balance the strong points of the worker
Flexible
Intelligent
Accurate
Repetitive
with those of the machine
5 november 2008
Evoluon - Eindhoven OMRON
Basics of LCIA assembly
•Flexible number of operators in line•Make many products in one line•Quick change over time•Easy to train operators •Standing style operations
Productivity Quality Flexibility•One-piece flow, fixed # WIP•Standardized labor•Ergonomically sound•everything in a fixed place (5S)•LCIA solutions•Fool-proof (Poka-Yoke) solutions
•Efficient work allocation•Teamwork •Paced to (stable) cycle time•Easy & not disturbing material replenishment from outside•Visual management
Line: CPM1A-V1 Buffer Safety Quality Scale:
Version: 2.2 (2 man) Standard Work Combination Sheet marking marking controlPitch Time: 112 dm - 127 dm 0.5 meter
4)
6) Final Test
5) CSA Test
PS-PCB
Con.opPS
Rear Case
Slid-ers
CPU PCB
Front-case
Perif Cov-
er
Labe
lP.
la.
Bo
ok
Package
1 2 3 4
5
6
710 9 81
1) 3)2) 2.1)
Guid
e led
7)8)10) 9)11)Complete
Paced to (stable) cycle timeStandardized labor
Fool-proof (Poka-Yoke) solutions
•Flexible number of operators in line
Standing style operations
5 november 2008
Evoluon - Eindhoven OMRON
LCIA effect
Productivity Quality Flexibility
CQM1 PLC assembly line:Cycle time reduction of 250%
5 november 2008
Evoluon - Eindhoven OMRON
LCIA effect
Productivity Quality FlexibilityFrom:•Manual visual check•Avg 63 customer complaints per year•Estimated >1000 defects per year
Wrong colorIntensity
To•Low cost vision system•Zero defect &Inspection time reduction (20 sec)
No illuminationLED allways on
5 november 2008
Evoluon - Eindhoven OMRON
LCIA effect
Productivity Quality Flexibility
35 different product in one line with change over time <30 sec.
5 november 2008
Evoluon - Eindhoven OMRON
Design process
• Line design very early in the product development process• Use Process FMEA to predict possible fault causes• Decide necessary tools based on FMEA level• Detailed Line Design and assembly• Test runs, measure designed cycle times, optimization
5 november 2008
Evoluon - Eindhoven OMRON
• Thank you for your attention